Method for making tires for vehicle wheels

ABSTRACT

A first carcass ply ( 3 ) is formed by depositing onto a toroidal support ( 11 ), strip-like lengths ( 13 ) cut to size from a continuous strip-like element and each comprising longitudinal thread-like elements ( 14 ) incorporated into a layer of elastomer material ( 17 ). The strip-like lengths are laid down sequentially in mutual circumferential side by side relationship, to form side portions ( 25 ) partly superposed on each other and crown portions ( 24 ) in mutual circumferential side by side relationship. Associated with the carcass ply ( 3 ) are annular structures ( 4 ) comprising a first and a second circumferentially inextensible annular inserts ( 27, 28 ) and an elastomer filling ( 29 ) interposed therebetween. A second carcass ply ( 31 ) is made in superposed position to the first carcass ply ( 3 ) and the annular structures ( 4 ). A belt structure ( 5 ), a tread band ( 8 ) and sidewalls ( 9 ) are combined with the carcass structure ( 2 ) thus formed, to define a tire ( 1 ) to be vulcanized.

This is a continuation of application Ser. No. 09/840,095, filed Apr.24, 2001 (now U.S. Pat. No. 7,041,185), which is a continuation ofapplication Ser. No. 09/219,422, filed Dec. 23, 1998 (now abandoned);additionally, Applicants claim the right of priority under 35 U.S.C.§119(a)-(d) based on Application No. 97830731.2, filed Dec. 30, 1997, inthe European Patent Office, the contents of which are incorporatedherein by reference; Further, Applicants claim the benefit under 35U.S.C. §119(e) based on prior-filed Provisional Application No.60/098,376, filed Aug. 28, 1998, in the U.S. Patent and TrademarkOffice; the contents of which are relied upon and incorporated herein byreference.

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to a method of making tires for vehiclewheels, comprising the steps of: manufacturing a carcass structure;optionally associating a belt structure with the carcass structure at acircumferentially external position thereof; associating a tread bandwith the belt structure at a circumferentially external positionthereof; associating at least one pair of sidewalls with the carcassstructure at laterally opposite positions; vulcanizing the obtainedtire.

Manufacture of tires for vehicle wheels involves formation of a carcassstructure essentially consisting of one or more carcass pliessubstantially having a toroidal conformation and the axially oppositeside edges of which engage respective circumferentially inextensibleannular reinforcing elements called “bead cores”.

Applied to the carcass structure, at a circumferentially externalposition thereof, is a belt structure comprising one ore more beltstrips in the form of a closed ring, essentially consisting of textileor metal cords suitably oriented relative to each other and to the cordsbelonging to the adjacent carcass plies.

A tread band currently consisting of a strip of elastomer material ofappropriate thickness is applied to the belt structure, at acircumferentially external position thereof.

It is to point out that, to the aims of the present invention, by theterm “elastomer material” it is intended a rubber blend in its entirety,that is the assembly made up of a base polymer suitably amalgamated withmineral fillers and/or additives of any other type.

Finally, to the opposite sides of the tire being manufactured a pair ofsidewalls are applied, each of them covering a side portion of the tireincluded between a so-called shoulder region, located close to thecorresponding side edge of the tread band, and a so-called bead locatedat the corresponding bead core.

In accordance with traditional production methods, essentially the abovelisted tire components are first made separately from each other to bethen assembled during a tire-manufacturing step.

For instance, for making the carcass ply or plies to be associated withthe bead cores to form the carcass structure, production of a rubberizedfabric comprising longitudinally-disposed continuous textile or metalliccords, through an extrusion and/or calendering process, is firstrequired. This rubberized fabric is submitted to a transverse-cuttingoperation to produce lengths of predetermined sizes that aresubsequently joined together so as to give rise to a continuousribbon-like semifinished product having transversely-disposed parallelcords.

Then this article of manufacture is to be cut into pieces the length ofwhich is correlated with the circumferential extension of the carcass tobe made.

Production methods have been recently proposed which, instead ofresorting to the production of semifinished products, make the carcassstructure directly during the tire-manufacturing step.

For example, U.S. Pat. No. 5,453,140 herein quoted as an example of themost pertinent state of the art, discloses a method and an apparatusforming a carcass ply starting from a single cord previously woundaround a reel.

According to the method and apparatus described in the above patent, ateach operating cycle of the apparatus the cord drawn from the reel bypower-driven idler rollers and maintained taut by a pneumatic tensioningsystem is cut to size to obtain a length of preestablished extension.

The cord length is picked up by a pick-up element mounted on a beltwound over power-driven pulleys to be extended transversely on the outersurface of a toroidal support.

The length ends are then engaged by bending members of the belt typeoperating on the opposite sides of the toroidal support for radiallyapplying the cord length to the toroidal support by means of slideelements acting like fingers along the side portions of the cord length.

Repetition of the above described operating cycle leads to deposition ofa number of cord lengths disposed circumferentially in side by siderelationship until the whole circumferential extension of the toroidalsupport has been covered.

Necessarily, the toroidal support is previously coated with a layer ofraw rubber having a dual function, i.e. that of adhering to the cordsdeposited thereon so as to conveniently hold them in a fixedpositioning, and that of constituting an inner liner impervious to airin the finished tire.

Tires obtained by this production method have a carcass structure inwhich the carcass ply or plies consist of individual cords each havingtwo side portions axially spaced apart from each other and orientedradially of the rotation axis of the tire, and a crown portion extendingat a radially outer position between the side portions.

Within the scope of the carcass structure manufacture, it is also knownthat close to each of the tire beads, the opposite ends of theindividual cords forming a carcass ply are located, in an alternatingsequence, at axially opposite positions relative to an annular anchoringelement forming said bead core, as can be learnt from patent EP 0 664231.

In accordance with the present invention, within the tire-manufacturingscope remarkable advantages have been found to be achieved if thecarcass ply or plies are made by depositing strip-like lengths insteadof individual cords, each of said lengths essentially comprising a layerof raw elastomer material incorporating two or more parallel thread-likeelements disposed longitudinally.

SUMMARY OF THE INVENTION

In more detail, the invention relates to a method of making a tire forvehicle wheels, wherein manufacturing of the carcass structure involvesformation of at least one first carcass ply by the following steps:preparing strip-like lengths each comprising longitudinal and parallelthread-like elements at least partly coated with at least one layer ofraw elastomer material; depositing each of the strip-like lengths onto atoroidal support in a substantially U-shaped conformation about theprofile in transverse section of the toroidal support, to define twoside portions substantially extending in planes orthogonal to ageometric axis of rotation of the toroidal support at mutually spacedapart positions in an axial direction, and a crown portion extending ata radially outer position between the side portions, wherein the crownportions of each strip-like length are disposed consecutively in side byside relationship along the circumferential extension of the toroidalsupport, whereas the side portions of each strip-like length are eachpartly covered with a side portion of at least one circumferentiallyconsecutive length.

Preferably, preparation of said strip-like lengths is carried out bycutting actions executed sequentially on at least one continuousstrip-like element incorporating said thread-like elements in said layerof raw elastomer material.

In addition, each cutting action is preferably provided to be followedby deposition of the individual length thus obtained onto the toroidalsupport.

In more detail, the side portions belonging to circumferentiallycontiguous lengths on the toroidal support are caused to mutuallyconverge at the geometric axis of rotation of the toroidal supportitself.

Advantageously, covering of the side portions of the strip-like lengthsprogressively decreases starting from a maximum value at radially innerends of the side portions until a zero value at transition regionsbetween said side portions and crown portions.

In a preferential solution the individual strip-like lengths aresequentially deposited onto the toroidal support according to acircumferential distribution pitch corresponding to the width of thestrip-like element.

In accordance with a possible alternative embodiment, the individualstrip-like lengths are sequentially deposited onto the toroidal supportaccording to a circumferential distribution pitch corresponding to amultiple of the width of the strip-like element.

Preferably, each strip-like length has a width corresponding to asubmultiple of the circumferential extension of the toroidal support, asmeasured at an equatorial plane thereof.

According to a further aspect of the invention, accomplishment of saidat least one first carcass ply further involves a step of sequentiallypressing the strip-like element at its side portions, to define regionsof increased width close to the inner circumferential edges of thecarcass structure.

Said pressing step can be optionally carried out on the continuousstrip-like element before executing the cutting action.

Concurrently with said pressing step, moving apart from each other ofthe thread-like elements comprised in the strip-like element is carriedout.

During the deposition step, at least one of the strip-like lengths maybe advantageously held on the toroidal support by a suction actionproduced through the toroidal support.

In particular, formation of each strip-like length involves the stepsof: laying down the strip-like length transversely and at a centeredposition relative to an equatorial plane of the toroidal support;radially moving the strip-like length close to the toroidal support soas to form the crown portion of the length on the toroidal support;translating the opposite ends of the strip-like length substantiallyradially close to the geometric axis of rotation of the toroidal supportfor applying the side portions of the strip-like length to the toroidalsupport; rotating the toroidal support relative to the distributorelement through an angular pitch corresponding to the circumferentialdistribution pitch of the strip-like lengths.

A step of pressing said side portions of the strip-like lengths againstthe side walls of the toroidal support may be also provided.

Advantageously, accomplishment of the carcass structure furthercomprises the step of applying at least one inextensible annularstructure to a region close to each of the inner circumferential edgesof the carcass ply obtained from the deposition step.

According to a possible embodiment, accomplishment of the carcassstructure further comprises the step of forming a second carcass plysuperposed on the first carcass ply and the circumferentiallyinextensible annular structures.

Formation of the second carcass ply may advantageously take place in thesame manner as accomplishment of the first carcass ply.

Formation of the carcass ply or plies may be preceded by a step ofcoating the toroidal support with at least one sealing layer made of anelastomer material impervious to air.

This coating step is advantageously carried out by winding at least oneribbon-like band of an air-proof elastomer material in coils disposedside by side along the profile in transverse section of the toroidalsupport.

In addition to, or in place of formation of the sealing layer, thefollowing steps may be provided to be carried out before thevulcanization step: disengaging the tire from the toroidal support;introducing an air tube into the carcass structure.

During said vulcanization step, a step of stretching said carcass pliesand belt strips may be advantageously carried out for achieving anexpansion of the tire of a linear amount included between 2% and 5%.

In accordance with a further innovatory aspect of the invention, to beadvantageously adopted also independently of the innovatory features setout hereabove, accomplishment of each inextensible annular structurecomprises the steps of: depositing at least one first elongated elementin concentric coils into a molding cavity in view of forming a firstcircumferentially inextensible annular insert substantially in the formof an annulus; depositing at least one second elongated element inconcentric coils into the molding cavity in view of forming a secondcircumferentially inextensible annular insert substantially in the formof an annulus disposed coaxially in side by side relationship relativeto the first annular insert; forming at least one filling body of rawelastomer material in the molding cavity, which filling body isinterposed between, and intimately joined to the first and secondcircumferentially inextensible annular anchoring elements.

Each of the inextensible annular structures made as above described maybe conveniently provided to be interposed between the first carcass plyand the second carcass ply.

Each of said deposition steps of the first and/or second elongatedelement can be conveniently preceded by a rubberizing step in which saidfirst and/or second elongated element is coated with at least one layerof raw elastomer material.

Preferably, also provided is a step of magnetically retaining the firstand/or second circumferentially inextensible annular insert, at apredetermined position, within the molding cavity.

Formation of said filling body may advantageously comprise the steps of:interposing at least one annular element of raw elastomer material of apredetermined volume between the first and second inextensible annularinserts; reducing the volume of the molding chamber in order to compresssaid annular element of elastomer material between the first and secondinextensible annular inserts and deform it until it fills said moldingchamber.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages will be best understood from thedetailed description of a preferred but non-exclusive embodiment of amethod of manufacturing a tire for vehicle wheels according to thepresent invention. This description will be taken hereinafter withreference to the accompanying drawings, given by way of non-limitingexample, in which:

FIG. 1 is a fragmentary perspective view in split of a tire inaccordance with the present invention;

FIGS. 2 to 5 diagrammatically show an apparatus for making the carcassply, according to different operating steps respectively, seen in adirection orthogonal to a diametrical section plane of a toroidalsupport carrying the tire during the manufacturing step;

FIG. 6 is a diagram showing manufacture of a continuous strip-likeelement intended for forming the carcass ply or plies;

FIG. 7 shows an embodiment of said strip-like element in transversesection;

FIG. 8 is a fragmentary perspective view diagrammatically showing thedeposition sequence of strip-like lengths for the purpose of forming afirst carcass ply of the tire in accordance with the invention;

FIG. 9 is a fragmentary diametrical section view of an inextensibleannular structure to be inserted at the tire bead, during a molding stepfor manufacturing the tire;

FIG. 10 is a fragmentary perspective view of an inextensible annularstructure laterally applied between a first and a second carcass plies;

FIG. 11 is a diagram showing the carcass structure of a tire inaccordance with the invention, seen laterally and in phantom forhighlighting the mutual arrangement of the portions in superposedrelationship of the individual strip-like lengths belonging to twodifferent carcass plies;

FIG. 12 is a transverse half-section showing a conventional tire mountedon a respective mounting rim and in a condition of slip running andpartial deflation;

FIG. 13 is a transverse half-section showing a tire according to theinvention mounted on a respective mounting rim and in a condition ofslip running and partial deflation.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the drawings, a tire for vehicle wheels made by amethod according to the present invention has been generally identifiedby reference numeral 1.

Tire 1 essentially comprises a carcass structure 2 having at least onefirst carcass ply 3 having a substantially toroidal conformation and inengagement, by its opposite circumferential edges, with a pair ofinextensible annular structures 4, each of which is located, when thetire has been completed, at the region usually identified as “tirebead”.

Applied to the carcass structure 2 at a circumferentially outer positionthereof, is a belt structure 5 comprising one or more belt strips 6 a, 6b and 7. A tread band 8 is circumferentially superposed on the beltstructure 5 and longitudinal and transverse cuts 8 a are formed in saidtread band 8, following a molding operation carried out concurrentlywith the tire vulcanization, and such disposed as to define a desired“tread pattern”.

The tire also comprises a pair of so-called “sidewalls” 9 appliedlaterally to opposite sides of the carcass structure 2.

The carcass structure 2 may possibly be coated, on its inner walls, witha sealing layer 10, i.e. a so-called “liner”, essentially consisting ofa layer of elastomer material impervious to air, adapted to ensure thehermetic seal of the inflated tire.

Assembling of the above listed components, as well as production of oneor more of said components, takes place with the aid of a toroidalsupport 11, diagrammatically shown in FIGS. 2 to 5, having the sameconfiguration as the inner walls of the tire to be manufactured.

In a preferential solution the toroidal support 11 has reduced sizesrelative to those of the finished tire, according to a linear amountpreferably included between 2% and 5%, measured, just as an indication,along the circumferential extension of the support itself at anequatorial plane X-X thereof which is coincident with the equatorialplane of the tire.

The toroidal support 11, which is not described or illustrated in detailin that it is not particularly of importance to the purposes of theinvention, may for example consist of a collapsible drum or aninflatable chamber or bladder suitably reinforced, so that it may takeand maintain the desired toroidal conformation under inflationconditions.

After taking into account the above statements, manufacture of tire 1first involves formation of the carcass structure 2 starting withoptional formation of the sealing layer or liner 10.

This liner 10 can be advantageously made by circumferentially windingabout the toroidal support 11, at least one ribbon-like band 12 of anair-proof elastomer material, produced from an extruder and/or acalendar located close to the toroidal support itself. As viewed fromFIG. 1, winding of the ribbon-like band 12 substantially takes place incircumferential coils disposed consecutively in side by siderelationship to follow the profile in transverse section of the outersurface of the toroidal support 11.

For descriptive purposes, by “profile in transverse section” it isherein intended a configuration exhibited by the half-section of thetoroidal support 11 sectioned along a plane radial to a geometricrotation axis thereof, not shown in the drawings, which is coincidentwith the geometric axis of rotation of the tire being manufactured.

Concurrently with winding of the ribbon-like band 12, application of apair of auxiliary annular elements 12 a can be carried out close to theinner circumferential edges of the carcass structure during itsmanufacturing step. Each of these auxiliary annular elements 12 a can beobtained for example by winding the ribbon-like band 12 in a coildisposed axially side by side with the corresponding coil located at theinner parametric edge of liner 10 defined or to be defined on thetoroidal support 11. Alternatively, the auxiliary annular elements 12 acan be made up of at least one auxiliary ribbon-like band obtained froma respective extruder located at the toroidal support 11.

In accordance with the present invention, the carcass ply 3 is directlyformed on the toroidal support 11 by depositing thereon, as betterclarified in the following, a plurality of strip-like lengths 13obtained from at least one continuous strip-like element 2 a preferablyhaving a width included between 3 mm and 20 mm.

As shown in FIG. 6, preparation of the continuous strip-like element 2essentially involves that two or more thread-like elements 14, andpreferably three to ten thread-like elements 14, fed from respectivereels 14 a, should be guided through a first extruder 15 associated witha first extrusion apparatus 16 carrying out feeding of raw elastomermaterial through the extruder itself.

It is pointed out that, in the present description by “extruder” it isintended that part of the extrusion apparatus, also identified in thisparticular field by the term “extrusion head”, provided with a so-called“die” passed through by the product being worked at an outlet portshaped and sized according to the geometrical and dimensional featuresto be given to the product itself.

The elastomer material and thread-like elements 14 are intimately joinedtogether within the extruder 15, thereby generating the continuousstrip-like element 2 a at the outlet thereof, which element is formed ofat least one layer of elastomer material 17 in the thickness of whichthe thread-like elements themselves are incorporated.

Depending on requirements, it is possible to guide the thread-likeelements 14 in the extruder 15 in such a manner that they are notintegrally incorporated into the layer of elastomer material 17 butappear on one or both surfaces thereof.

The thread-like elements 14 may each consist for example of a textilecord preferably having a diameter included between 0.6 mm and 1.2 mm, ora metallic cord preferably having a diameter included between 0.3 mm and2.1 mm.

Advantageously, if required, the thread-like elements 14 can be disposedin the continuous strip-like element 2 a in such a manner that they givethe carcass ply 3 thus obtained unexpected qualities of compactness andhomogeneity. For the purpose, the thread-like elements 14 can be forexample disposed according to a density greater than six thread-likeelements/centimeter, measured circumferentially on the carcass ply 3close to the equatorial plane X-X of tire 1. In any case it ispreferably provided that the thread-like elements 14 should be disposedin the strip-like element 2 a according to a mutual distance betweencenters not lower than 1.5 times the diameter of the thread-likeelements themselves, in order to enable an appropriate rubberizingoperation between the adjacent threads.

The continuous strip-like element 2 a coming out of extruder 15 can beadvantageously guided, optionally through a firstaccumulator-compensator device 18, on a deposition apparatus 19diagrammatically shown in FIGS. 2 to 5.

The deposition apparatus 19 essentially comprises first guide members20, consisting for example of a pair of opposite rollers intended forengagement of the continuous strip-like element 2 a produced by theextruder 15, downstream of the accumulator-compensator device 18.

Downstream of the first guide members 20, the strip-like element 2 acomes into engagement with a first grip member 21 movable in a directionoriented transversely to the equatorial plane X-X of the toroidalsupport 11.

In more detail, the first grip member 21 is movable between a firstoperating position in which, as shown in FIG. 2, it engages one end ofthe continuous strip-like element 2 a close to the first guide membersconsisting of opposite rollers 20, and a second operating position inwhich, as shown in FIG. 3, it is moved apart from the first guide memberin order to lay down the continuous strip-like element 2 a transverselyof the equatorial plane X-X of the toroidal support 11.

When the first grip member 21 has reached the second operating position,a second grip member 22 engages the continuous strip-like element 2 aclose to the first guide members 20.

Then, a cutting member 23 is operated and it cuts the continuousstrip-like element 2 a at a stretch thereof included between the secondgrip element 22 and the first guide members 20, giving rise to formationof a strip-like length 13 of a predetermined extension “L”.

Following the cutting action by the cutting member 23, the obtainedstrip-like element 13 is laid down transversely and at a centeredposition relative to the equatorial plane of the toroidal support.

Afterwards, the grip members 21 and 22 are simultaneously translated inthe direction of the geometric axis of the toroidal support 11 byradially moving the strip-like length 13 close to the toroidal support.Under this circumstance, formation of a crown portion 24 takes place ata centered position on the longitudinal extension of the strip-likelength 13, which portion extends at a radially outer position on thetoroidal support 11.

As clearly viewed from FIG. 4, as the radial movement of the gripmembers 21 and 22 goes on the opposite ends of the strip-like length 13are moved radially close to the geometric axis of rotation of thetoroidal support 11, giving rise to formation of two side portions 25substantially extending in planes orthogonal to the geometric axis ofrotation of the toroidal support, at positions axially spaced apart fromeach other.

By a possible subsequent movement of the grip members 21 and 22 close tothe toroidal support 11, the opposite ends of the strip-like element aredefinitively applied to the toroidal support 11 so that deposition oflength 13 is completed, this length taking a substantially U-shapedconfiguration about the profile in transverse section of the toroidalsupport.

Components intended for support and guided movement of the grip members21 and 22 are not shown in the accompanying drawings as they can be madein any manner convenient for a person skilled in the art, and in anycase they are not of importance to the aims of the present invention.

If required, the side portions 25 of the strip-like length can besubmitted to a pressing step against the side walls of the toroidalsupport 11. For the purpose, a pair of pressing rollers or equivalentmeans not shown may be provided for operation on the opposite sides ofthe toroidal support 11, which rollers are each arranged to act on therespective side portion 25 by a thrust action and simultaneous radialsliding towards the geometric axis of rotation of the toroidal support11.

Due to the sticky character of the raw elastomer material forming layer17 coating the thread-like elements 14, a steady adhesion of thestrip-like length 13 to the surfaces of the toroidal support 11 isensured, even in the absence of liner 10 on said toroidal support. Inmore detail, the above described adhesion takes place as soon as thestrip-like length 13 comes into contact with the toroidal support 11 ata radially external region of its profile in transverse section.

In addition to, or in place of the above described exploitation of thenatural sticky character of the elastomer material, holding of one ormore strip-like lengths 13 on the toroidal support 11 can be obtained bycarrying out a suction action produced through one or more appropriateholes 26 arranged on the toroidal support.

The toroidal support 11 can be driven in angular rotation according to astep-by-step movement in synchronism with operation of the depositionapparatus 19, in such a manner that at each cutting action of eachstrip-like length 13 deposition of the latter onto the toroidal supporttakes place in a circumferential side by side relationship with thestrip-like length 13 previously deposited.

In the embodiment diagrammatically shown in the accompanying figures,where the circumferential distribution pitch of the individualstrip-like lengths 13 corresponds to the width of same, theangular-rotation pitch of the toroidal support 11 will correspond to thewidth of said lengths.

However, the circumferential distribution pitch of the strip-likelengths 13 may be provided to correspond to a multiple of their width.In this case, the angular-movement pitch of the toroidal support 11 willcorrespond to said circumferential distribution pitch. It is to pointout that, to the aims of the present invention, when it is not otherwisestated, the term “circumferential” refers to a circumference lying inthe equatorial plane X-X and close to the outer surface of the toroidalsupport 11.

Due to the above described operating sequence of the depositionapparatus 19, in the first carcass ply 3 obtained the crown portions 24of each strip-like length 13 are disposed consecutively in side by siderelationship along the circumferential extension of the toroidal support11, whereas each of the side portions 25 of each length 13 is partlysuperposed with the side portion 25 of at least one length 13 previouslylaid down, and also partly covered with the side portion 25 of at leastone length 13 laid down subsequently. In the accompanying figures, theoverlapping regions of the strip-like lengths 13 forming the firstcarcass ply 3 are identified by 13 a.

As clearly shown in FIG. 8, the side portions 25 in mutual superpositionrelationship move towards each other substantially in the direction ofthe geometric axis of rotation of the toroidal support 11, at an angle δthe value of which is correlated with the width “W” of the strip-likeelements 13, and in any case with the circumferential distribution pitchthereof, as well as with the value of a maximum radius R to be measuredat a point of maximum distance from the geometric axis of rotation ofthe toroidal support 11.

Due to the mutual convergence between the contiguous side portions 25,mutual superposition or covering of same, i.e. the circumferential widthof the overlapping regions 13 a, progressively decreases starting from amaximum value at the radially inner ends of the side portions, until azero value at the transition region between the side portions 25 andcrown portions 24.

It is to note that, due to the difference between the maximum radius Rand a minimum radius R′, to be measured at a point of minimum distancefrom the geometric axis of rotation of the toroidal support 11, theaverage density of the thread-like elements 14, i.e. the amount of thethread-like elements 14 present in a circumferential section of givenlength, progressively increases on moving close to said geometricrotation axis.

Actually, this increase in density is proportional to the ratio valuebetween the maximum radius R and minimum radius R′.

It is also to note that the thread-like elements 14 belonging to twomutually superposed side portions 25 are disposed in respectivelycrossed orientations at an angle corresponding to said angle δ, incorrelation not only with the value of the maximum radius R, but alsowith the width of the individual lengths 13 and the circumferentialdistribution pitch thereof.

If, depending on requirements, one wishes to modify the crossing angleof the thread-like elements 14, a pressing step may be provided to beexecuted on the continuous strip-like element 2 a in the regions of itslongitudinal extension corresponding to the ends of the strip-likeelements 13 to be obtained from said cutting actions. In this mannerregions of greater width located at the inner circumferential edges ofthe formed carcass ply 3 are defined on the extension of each strip-likelength 13.

Said pressing action can be carried out by said guide rollers 20 or anauxiliary pressing roller (not shown) adapted to press the continuousstrip-like element 2 a in order to cause pressing of same at thelongitudinal-extension sections intended to form the side portions 25 ofthe individual lengths 13. The pressing action causes a reduction in thethickness of the elastomer layer 17 and an increase in the width of thestrip-like element 2 a which, as a result, will make the thread-likeelements 14 move apart from each other.

By suitably inclining the orientation of the geometric axis of rotationof the toroidal support 11 relative to the movement direction of thefirst grip member 21, the crown portions 24 of lengths 23 can be given adesired inclination, included, by way of example, between 0° and 25°relative to a radial plane passing by the geometrical axis. In moredetail, this inclination may be advantageously included between 0° and3° if tire 1 is provided with only one carcass ply 3, or between 10° and20°, and more preferably it may correspond to 15° if, as provided in theembodiment herein illustrated, the carcass structure is comprised of twocarcass plies 3, 31.

Accomplishment of a carcass structure 2 generally comprises the step ofapplying said inextensible annular structure 4 to an area close to eachof the inner circumferential edges of the carcass ply 3 obtained in thepreviously described manner, for the purpose of creating the carcassregions known as “beads”, which are specifically intended for ensuringanchoring of the tire to a corresponding mounting rim; in accordancewith a preferred embodiment of the tire, the carcass ply thereof isobtained in the above described manner.

Each of these inextensible annular structures 4 (FIG. 10) comprises afirst circumferentially inextensible annular insert 27, substantially inthe form of an annulus concentric with the geometric axis of rotation ofthe toroidal support 11 and situated adjacent to a corresponding innercircumferential edge of the first carcass ply 3.

The first annular insert 27 is made of at least one elongated metalelement wound up to form several substantially concentric coils 27 a.Coils 27 a can be defined by a continuous spiral or by concentric ringsformed of respective elongated elements.

Combined with the first annular insert 27 is a second circumferentiallyinextensible annular insert 28 substantially extending in the form of arespective annulus disposed coaxially in side by side relationship withthe first annular insert 27.

The second annular insert 28 too is preferably made of at least oneelongated metal element wound up to form several substantiallyconcentric coils 28 a that can be defined by a continuous spiral or byconcentric rings formed of respective elongated elements.

Preferably, the second annular insert 28 has a radial extension given bythe difference between the minimum inner radius and the maximum outerradius of the annular insert, which is greater than the radial extensionof the first annular insert 27.

Interposed between the first and second annular inserts 27, 28 is atleast one filling body 29 of elastomer material preferably having ahardness included between 70° and 92° Å Shore.

As better clarified in the following, during the tire use the abovedescribed annular structures 4 efficiently counteract tendency of thebeads to rotate about their resting points on the rim under the effectof slip thrusts directed parallelly to the rotation axis of tire 1. Thistendency to rotation is particularly apparent when the tire is employedunder conditions of partial or complete deflation.

Preferably, accomplishment of each annular structure 4 involvesformation of a first inextensible annular insert 27 within a moldingcavity 30 defined in a mold 30 a, 30 b, by deposition of at least oneelongated element in concentric coils 27 a disposed in mutual side byside relationship according to circumferences of increasingly growingdiameter about their geometric winding axis, corresponding to therotation axis of the tire.

This operation can be advantageously carried out through winding of theelongated element in a helical seating arranged in a first cheek 30 a ofthe mold 30 a, 30 b which for the purpose can be driven in rotationabout its own geometric axis.

Then a second annular insert 28 is located within the molding cavity 30,formation of which can advantageously take place in the same manner asdescribed for the first annular insert 27.

The deposition step of the elongated element or elements intended forformation of one or both annular inserts 27, 28 can be advantageouslypreceded by a rubberizing step during which the elongated element,preferably of metal material, is coated with at least one layer of rawelastomer material that not only ensures an excellent rubber-metal bondon the elongated element itself, but also promotes adhesion thereof fora steady placement in the above mentioned helical seating.

The first cheek 30 a and/or the second cheek 30 b may be alsoadvantageously provided to be made of a magnetic material, or to beactivated in an electromagnetic manner so as to conveniently attract andretain the respective elongated element, thereby ensuring a steadypositioning of coils 27 a and/or 28 a as and when they are formed.

Then, the filling body 29 is formed within the molding cavity 30.Forming of said body may be conveniently carried out by interposing atleast one annular element of raw elastomer material of predeterminedvolume between the first and second annular inserts 27, 28 formed on therespective cheeks 30 a, 30 b. This annular element can have anyconvenient conformation in transverse section, provided its volumecorresponds to the inner volume of the molding chamber 30 when cheeks 30a, 30 b are moved close to each other in a closed condition of the mold.

Once the annular element has been positioned between cheeks 30 a, 30 b,closure of the molding cavity 30 by mutual approaching of the cheeks iscarried out. Under this circumstance, the volume of the molding cavity30 is reduced, so that the annular element of raw elastomer material ispressed between the first and second annular inserts 27, 28 beingsubmitted to deformation until it completely fills the molding cavity,thereby forming the filling body 29 which is intimately joined to thefirst and second annular inserts 27, 28.

As an alternative solution to the above, formation of the filling body29 can be carried out for example by filling the molding cavity 30 withelastomer material introduced by injection or any other mannerconvenient for a person skilled in the art, after moving cheeks 30 a, 30b close to each other.

The above described accomplishment of the inextensible annularstructures 4 can advantageously take place close to the toroidal support11, so that said structures can be directly removed from mold 30 a, 30 band laterally applied to the first carcass ply 3 by appropriatemechanical handling devices not described as not of importance to theaims of the invention.

In accordance with a further preferential feature of the invention,accomplishment of the carcass structure 2 further involves formation ofat least one second carcass ply 31. Advantageously, this second carcassply 31 can be formed directly upon the first carcass ply 3 and theinextensible annular structures 4, so that, as clearly shown in FIG. 10,the second annular insert 28 of each annular structure 4 is disposed incontact with an inner surface of the second carcass ply.

In accordance with a possible alternative solution, accomplishment ofeach annular structure 4 may first involve formation of the firstannular insert 27 alone joined to the filling body 29, to carry outapplication of the second annular insert 28 subsequently to formation ofthe second carcass ply 31. In this case, each of the innercircumferential portions of the second carcass ply 31 is interposedbetween the respective filling body 29 and the second annular insert 28,which is applied to the outer surfaces of the second carcass ply itself,in contact relationship therewith.

Preferably the second carcass ply 31 is manufactured in such a mannerthat it has its respective thread-like elements 32 disposed according toa crossed orientation relative to the thread-like elements 14 belongingto the first carcass ply 3.

In more detail, formation of the second carcass ply 31 convenientlytakes place in the same manner as previously described with reference tomanufacturing of the first carcass ply 3, i.e. by sequential depositionof respective strip-like lengths 33, to define respective crown portions34 disposed consecutively in side by side relationship in acircumferential direction and side portions 35 each partly covered bythe side portion 35 of the adjacent strip-like length 33. In theaccompanying figures, the covering or mutual-superposition regions ofthe strip-like lengths 33 forming the second carcass ply 31 are denotedby 33 a.

Conveniently, the strip-like lengths 33 of the second carcass ply 31 arelaid down according to a crossed orientation relative to the strip-likelengths 13 forming the first carcass ply. In addition, it is preferablyprovided that inclination of the strip-like lengths 33 of the secondcarcass ply 31, with reference to the equatorial plane X-X, shouldsubstantially have the same value as the inclination of the strip-likelengths 13 belonging to the first carcass ply 3.

In tires of the radial type, a belt structure 5 is currently applied tothe carcass structure 2.

This belt structure 5 may be made in any manner convenient for a personskilled in the art and in the embodiment shown it essentially comprisesa first and a second belt strips 6 a, 6 b having cords with arespectively crossed orientation. Superposed on the belt strips is anauxiliary belt strip 7, for instance obtained by winding at least onecontinuous cord in coils disposed axially side by side on the first andsecond belt strips 5, 6.

Then the tread band 8 and sidewalls 9, which are also obtained in anymanner convenient for a person skilled in the art, are applied to thebelt structure 5.

Embodiments of a belt structure, sidewalls and a tread band that can beadvantageously put into practice for a complete accomplishment of thetire in reference on the toroidal support 11 are described in theEuropean Patent Application No. 97830632.2 in the name of the sameApplicant.

Tire 1 as manufactured and after removal of same from support 11, can benow submitted to a vulcanization step that can be carried out in anyknown and conventional manner.

According to a possible alternative solution, an air tube of closedtubular section may be advantageously associated with tire 1 in additionto, or in place of liner 10, before the vulcanization step, which airtube is inserted into carcass 2 after the tire has been removed from thetoroidal support 11. This air tube, not shown in the accompanyingdrawings, will be inflated after the tire has been introduced into avulcanization mold, to supply an inner pressure adapted to ensure aperfect adhesion of the tire against the mold walls and, in particular,against the mold parts intended for defining the longitudinal andtransverse cuts 8 a of the tread pattern.

According to a further preferential feature of the present invention,during the vulcanization step the carcass plies 3, 31 and belt strips 6a, 6 b, 7 are submitted to a stretching step to achieve a pre-tensioningthereof, giving rise to a tire expansion of a linear amount, measured onthe circumferential extension at the equatorial plane X-X of the tireitself, included by way of example between 2% and 5%. This stretchingstep can be achieved by effect of the inflation pressure of the abovementioned air tube, or other type of inflatable chamber or bladderemployed in the vulcanization apparatus.

The present invention achieves important advantages.

Actually, the tire in reference can be obtained through manufacture ofthe different components directly on a toroidal support on which thetire is gradually formed or in any case very close thereto. In this wayall problems connected with manufacture, storage and management ofsemifinished products which are common to manufacturing processes of thetraditional type are eliminated.

It is to note in particular that formation of the carcass ply or pliesby deposition of strip-like lengths each formed of several cordsincorporated into one elastomer layer enables important advantages to beachieved. First of all, in comparison with the method described in theabove mentioned U.S. Pat. No. 5,362,343, the manufacturing time for eachcarcass ply can be greatly reduced, due to the simultaneous depositionof as many thread-like elements as they are contained in each strip-likelength 13 or the continuous strip-like element 2 a from which lengths 13come. Employment of the strip-like lengths 13 also dispenses with theneed for previously depositing liner 10 onto the toroidal support.Actually, the elastomer layer 17 employed in forming the continuousstrip-like element 2 a is capable by itself of ensuring an efficientadhesion of element 2 a to the toroidal support 11, thereby ensuring asteady positioning of the individual lengths 13, 33.

Positioning accuracy as regards strip-like lengths 13, 33 andthread-like elements integrated thereinto is further improved by thefact that each strip-like length has an important structural consistencythat makes it insensitive to vibrations or similar oscillation effectswhich can be transmitted by the deposition apparatus 19. In thisconnection it is to note that deposition of individual cords, asdescribed in U.S. Pat. No. 5,362,343, may be somewhat problematic, dueexactly to vibrations and/or oscillations undergone by said cords duringthe deposition step.

Furthermore, simultaneous deposition of a plurality of thread-likeelements in accordance with the invention enables the depositionapparatus 19 to be operated at slower rates than required whendeposition of individual cords is concerned, which is a furtheradvantage in terms of working accuracy without on the other handimpairing productivity.

Besides, deposition of strip-like lengths directly crownwise to atoroidal support of a profile substantially identical with that of thefinished tire enables densities to be achieved that cannot be reached inthe art by known methods providing deposition of a carcass ply in theform of a cylindrical sleeve and subsequent shaping of same into atoroidal form, which will consequently bring about thinning of thecarcass ply cords disposed crownwise to the finished tire.

In addition to the above, each strip-like length can be steadilyfastened to the toroidal support by a vacuum effect produced throughpossible suction ducts 26, which steady fastening by vacuum cannot beachieved by known processes carrying out deposition of individual cords.

If required, the side portions of the strip-like lengths can be disposedat a suitably increased inclination relative to a direction radial tothe toroidal support axis, which will enable the expansion undergone bythe tire during the stretching step imposed to it on vulcanization to beefficiently helped. Actually, during this step, the side portions 25, 35tend to take an orientation in a plane radial to the tire together withthe crown portions 24, 34 extending between the side portions.

The construction and structure conception of the tire in question, aboveall with reference to its carcass structure 2, enables importantimprovements to be achieved in terms of structural strength, above allclose to the sidewalls and beads, where a greater structural strength isusually required, as well as in terms of behavior, above all inconnection with the effects of the slip thrusts that occur when tiresare run on bends.

Actually it is to note that, even if each carcass ply 3, 31 is takeninto account separately from the other carcass ply, the mutualsuperposition or partial covering of the strip-like lengths 13, 33 givesrise to a first structural strengthening at the tire sidewall regions.This strengthening is also promoted by the fact that, as abovedescribed, in the regions of mutual superposition of the strip-likelengths 13, 33, the thread-like elements 14, 32 belonging to the twolengths are disposed in mutually-crossed orientations.

The mutually-crossed orientation of the strip-like lengths 13, 33forming the first and second carcass plies 3, 31 respectivelyconstitutes a second strengthening factor for carcass structure 2. Thissecond strengthening factor partly results from the mutually-crossedarrangement provided for the thread-like elements 14, 32 belonging tothe first and second carcass plies 3, 31 respectively, and partlyresults from the mutually-crossed arrangement provided for the coveringor superposition regions 13 a, 33 a of lengths 13, 33 belonging to thefirst and second carcass plies.

This crossed arrangement of the superposition regions 13 a, 33 a isclearly shown in FIG. 11. From said figure one can easily understandthat the mutual-superposition regions 13 a, 33 a belonging to the firstand second carcass plies 3, 31 respectively, define a type of networkstructure giving the tire an exceptional structural strength. Inparticular, in this manner qualities such as resistance to accidentalshocks against pavement borders or the like for example, and tireresistance to torsional stresses about the rotation axis are improved,which will make the tire appropriate to withstand high torque valuesboth during acceleration and braking.

In addition to the above, the construction features of the inextensibleannular structures 4 are adapted to further increase the structuralstrength of the tire at the bead and sidewall regions.

Actually, the presence of the circumferentially inextensible annularinserts 27, 28 intimately joined to the carcass plies 3, 31 creates afurther “bond” between the mutually-crossed thread-like elements 14, 32belonging to the first and second carcass plies 3, 31. Thus, the carcassstructure 2 is further strengthened at the regions corresponding to thetire beads without for the purpose requiring employment of additionalstrip-like inserts, usually called “flippers”, wound like a slipknotabout the inextensible annular structures 4, said flippers being used onthe contrary in the known art.

From a comparison between FIGS. 12 and 13 one can easily notice theimprovement produced by the construction expedients described above inconnection with the tire behavior under the effect of slip thrustsdirected axially of the tire, generated when the tire is run on a bend,for example. For the sake of clarity, section hatching has beenintentionally omitted from the tires shown in FIGS. 12 and 13. It isalso to point out that, for better highlighting the phenomena triggeredby the slip thrusts, FIGS. 12 and 13 have been made with reference totires under conditions of partial deflation.

In more detail, FIG. 12 shows a tire 101 of the traditional type,mounted on a respective rim 100 that, in register with each tire bead,has a bead seat 100 a axially delimited by a flange 100 b defining anouter side edge of the rim and a security hump 100 c. The differentcomponents of tire 101 are marked by numeral indices obtained by adding100 to the numeral value of the indices previously employed forcorresponding parts of tire 1 in accordance with the invention.

In tire 101 made in accordance with the known art, the carcass ply orplies tend to bend at the tire sidewall under the effect of the slipthrust T, generated parallelly to the rotation axis of the tire byfriction of the tread band 108 on the ground, on a bend.

This slip thrust T, transmitted along the ply or plies 103 of thecarcass structure 102 up to the inextensible annular structures 104,generates a radial component Tr and an axial component Ts. The radialcomponent Tr is counteracted by the circumferential inextensibility ofthe annular structure 104 resting, over the whole circumferential volumethereof, on the respective seat 10 a provided in rim 100. The axialcomponent Ts, oriented towards the equatorial plane of the tire, tendsto move the tire bead away from the flange 100 b of rim 100 and isusually counteracted by the security hump 100 c. The radial sizes of thesecurity-hump are however rather limited and it may easily happen that,when the axial component Ts exceeds given values, the tire bead isremoved from its respective seat 100 a, instantaneously causing a fulldeflation and a consequent loss of functionality of tire 100. Thisphenomenon is also facilitated by the fact that the tire bead structuredin accordance with the known art, under the effect of the slip thrust T,tends to “roll” on the security hump 100 c.

The risks that the above described phenomenon of removal of the beadfrom its seat may occur are particularly important when the tire isforced to run under conditions of partial deflation, and the carcassstructure 102 is therefore subjected to undergo important deformationsunder the effect of the slip thrusts.

Referring now to the tire in reference shown in FIG. 13, the annularstructures 4 of the invention, interposed between the first and secondcarcass plies 3, 31, prevent the tire beads from rotating, under theeffect of the slip thrust T, around their resting point against therespective security humps 100 c provided in rim 100.

In more detail, it is to note that the presence of the circumferentiallyinextensible annular inserts 27, 28 located internally of, and directlyin contact with the respective carcass plies 3, 31 and mutually spacedapart by interposition of the filling body 29, efficiently prevents thebead from bending and rotating under the effect of slip thrusts.Actually, on examining FIG. 13 one can see that the slip thrust T wouldtend to bend the inextensible annular structure 4 towards the equatorialplane of tire 1. Under this circumstance, the first annular insert 27tends to be radially compressed, whereas the second annular insert 28 issubjected to a tensile stress in a radial direction. However, thecircumferential inextensibility of the individual coils 27 a, 28 aforming inserts 27, 28, as well as the intimate union of said insertswith the respective carcass plies 3, 31 having the respectivethread-like elements 14, 32 mutually crossed at the superpositionregions 13 a, 33 a, inhibit the capability of bending deformation of theinextensible annular structure 4 almost completely.

The slip force T is equitably shared between the first and secondcarcass plies and transmitted along said plies until the respectivefirst and second inextensible annular elements 27, 28 provided instructure 4.

Under this situation the slip force T portion transmitted along thefirst carcass ply 3 until close to the first annular insert 27 givesrise to a radial component Tr₁ tending to move the bead away from thebead seat 55 and counteracted by the circumferential inextensibility ofthe annular structure 4, as well as to an axial component Ts₁ tending topush the bead against the circumferential flange 53, thereby ensuringmaintenance of a steady positioning of said bead.

The slip force T portion transmitted along the second carcass ply 31generates a radial component Tr₂ as well, which is counteracted by thecircumferential inextensibility of the second annular insert 28, and anaxial component tending to push the bead against the flange 100 b butwhich has a practically zero value when, as in the case shown, the innercircumferential edge of the second carcass ply takes an orientationperpendicular to the tire axis.

A correct positioning of the bead is in any case ensured by the abovedescribed axial component Ts₁.

In this way the tire having beads made in accordance with the presentinvention can bear the so-called “J-curve Test” without removal of thebead from its seat until inflation pressures of 0.5 bar, whereas in theknown art tires that are unable to counteract bead displacements fromtheir seats at pressures lower than 0.8-1.0 bar are considered asacceptable.

It is also to note that the annular inserts 27 and 28 furnish a furtherstructural protection of the tire at the beads.

Increase in the structural strength at the sidewalls has beenadvantageously obtained without involving an excessive stiffening at thecarcass structure crown, where the lengths of each ply are disposedcircumferentially side by side in the absence of mutual superposition.This aspect is particularly advantageous with reference tohigh-performance lowered-profile tires where the structural strength ofthe sidewalls is greatly critical, also due to the high torque valuesthat the tire must be able to transmit.

1. A method of making a tire, the tire comprising a carcass structureand at least one circumferentially inextensible annular structure,comprising: forming at least one carcass ply of the carcass structure;forming the at least one annular structure; and applying the at leastone annular structure to a region close to inner circumferential edgesof the at least one carcass ply; wherein forming each carcass plycomprises: preparing a first and a last strip length; preparingintermediate strip lengths, each intermediate strip length comprisinglongitudinal and parallel thread elements at least partly coated with atleast one layer of raw elastomer material; and depositing theintermediate strip lengths onto a toroidal support in a substantiallyU-shaped conformation about a profile in transverse section of thetoroidal support; wherein each intermediate strip length comprises: twoside portions that substantially extend in planes orthogonal to ageometric axis of rotation of the toroidal support atmutually-spaced-apart positions in an axial direction; a crown portionthat extends at a radially outer position in a plane substantiallyparallel to the geometric axis of rotation of the toroidal support; andtwo mutually-axially-spaced-apart transition regions that are definedbetween the side portions and the crown portion, respectively; whereinthe crown portions of the intermediate strip lengths are disposedconsecutively in side-by-side relationship along a circumferentialextension of the toroidal support, wherein edges of circumferentiallyconsecutive intermediate strip lengths abut uniformly along their entirecrown portions extending between the transition regions, wherein eachside portion of each intermediate strip length covers in part a sideportion of a first circumferentially consecutive strip length and ispartly covered by a side portion of a second circumferentiallyconsecutive strip length, wherein forming the at least one annularstructure comprises depositing at least one first elongated element insubstantially concentric coils to form a first circumferentiallyinextensible annular insert, substantially in a form of an annulus, andwherein the respective side portions of the intermediate strip lengthsare not turned up around the first annular insert.
 2. The method ofclaim 1, wherein the intermediate strip lengths are prepared by cuttingactions executed sequentially on at least one continuous strip elementincorporating the thread elements in the at least one layer of rawelastomer material.
 3. The method of claim 2, wherein each cuttingaction is followed by deposition of an individual intermediate striplength thus obtained onto the toroidal support.
 4. The method of claim1, wherein the side portions of circumferentially consecutiveintermediate strip lengths on the toroidal support converge toward thegeometric axis of rotation of the toroidal support.
 5. The method ofclaim 1, wherein an amount of coverage of the side portions of theintermediate strip lengths progressively decreases, starting from amaximum value at radially inner ends of the side portions until a zerovalue at the transition regions.
 6. The method of claim 1, wherein theintermediate strip lengths are sequentially deposited onto the toroidalsupport according to a circumferential distribution pitch correspondingto a width of the intermediate strip lengths.
 7. The method of claim 1,wherein the intermediate strip lengths are sequentially deposited ontothe toroidal support according to a circumferential distribution pitchcorresponding to a multiple of a width of the intermediate striplengths.
 8. The method of claim 1, wherein the intermediate striplengths have a width corresponding to a submultiple of a circumferentialextension of the toroidal support, as measured at an equatorial plane ofthe toroidal support.
 9. The method of claim 1, further comprising:sequentially pressing the side portions of each intermediate striplength to define regions of increased width close to innercircumferential edges of the carcass structure.
 10. The method of claim9, wherein the intermediate strip lengths are prepared by cuttingactions executed sequentially on at least one continuous strip elementincorporating the thread elements in the at least one layer of rawelastomer material, and wherein sequentially pressing the side portionsis carried out on the at least one continuous strip element beforeexecution of corresponding cutting actions.
 11. The method of claim 9,further comprising: moving the thread elements in the intermediate striplengths apart from each other concurrently with sequentially pressingthe side portions.
 12. The method of claim 1, wherein during depositingthe intermediate strip lengths, at least one of the intermediate striplengths is held on the toroidal support by a suction action producedthrough the toroidal support.
 13. The method of claim 1, whereindepositing the intermediate strip lengths comprises: laying down eachintermediate strip length transversely and at a centered positionrelative to an equatorial plane of the toroidal support; radially movingeach intermediate strip length close to the toroidal support so as toform the crown portions of the intermediate strip lengths on thetoroidal support; translating opposite ends of each intermediate striplength substantially radially close to the geometric axis of rotation ofthe toroidal support for applying the side portions of the intermediatestrip lengths to the toroidal support; and rotating the toroidal supportthrough an angular pitch corresponding to a circumferential distributionpitch of the intermediate strip lengths.
 14. The method of claim 1,further comprising: pressing the side portions of the intermediate striplengths against side walls of the toroidal support.
 15. The method ofclaim 1, wherein forming the at least one carcass ply comprises: formingat least one first carcass ply; and forming at least one second carcassply superposed on the at least one first carcass ply.
 16. The method ofclaim 1, further comprising: coating the toroidal support with at leastone sealing layer or liner made of an elastomer material impervious toair prior to forming the at least one carcass ply.
 17. The method ofclaim 16, wherein coating the toroidal support is carried out by windingat least one ribbon band of an air-proof elastomer material in coilsdisposed side-by-side along the profile in transverse section of thetoroidal support.
 18. The method of claim 1, further comprising:disengaging the tire from the toroidal support; introducing an air tubeinto the carcass structure; and vulcanizing the tire.
 19. The method ofclaim 1, further comprising: vulcanizing the tire; and stretching thecarcass structure during vulcanizing to achieve an expansion of the tireof a linear amount between 2% and 5%.
 20. The method of claim 1, furthercomprising: depositing at least one second elongated element insubstantially concentric coils to form a second circumferentiallyinextensible annular insert substantially in a form of an annulusdisposed concentrically in a side-by-side relationship relative to thefirst annular insert; and forming at least one filling body of rawelastomer material interposed between the at least one first elongatedelement and the at least one second elongated element.
 21. The method ofclaim 20, wherein the at least one first elongated element and the atleast one second elongated element are deposited into a molding cavity,and wherein the at least one filling body is formed in the moldingcavity.
 22. The method of claim 20, wherein at least one of thesubstantially concentric coils of the first annular insert, the secondannular insert, or the first and second annular inserts is defined by acontinuous spiral of one or more elongated elements.
 23. The method ofclaim 20, wherein at least one of the substantially concentric coils ofthe first annular insert, the second annular insert, or the first andsecond annular inserts is defined by concentric rings of one or moreelongated elements.
 24. The method of claim 21, wherein the at least onefilling body is formed in the molding cavity by: interposing at leastone annular element of raw elastomer material of predetermined volumebetween the first and second annular inserts; and reducing a volume ofthe molding cavity to compress and deform the at least one annularelement until the at least one annular element, the at least one firstelongated element, and the at least one second elongated element fillthe molding cavity.
 25. The method of claim 21, wherein the at least onefilling body is formed in the molding cavity by injecting raw elastomermaterial between the first and second annular inserts.
 26. The method ofclaim 20, wherein each annular structure is interposed between at leastone first carcass ply and a second carcass ply superposed on the atleast one first carcass ply.
 27. The method of claim 20, furthercomprising: coating one or more of the at least one first and secondelongated elements with at least one layer of raw elastomer material;wherein each coated elongated element is coated prior to depositing thecoated elongated element.
 28. The method of claim 21, furthercomprising: magnetically retaining at least one of the first and secondannular inserts at a predetermined position within the molding cavity.29. A method of making a tire, the tire comprising a carcass structureand at least one circumferentially inextensible annular structure,comprising: forming at least one carcass ply of the carcass structure;forming the at least one annular structure; and applying the at leastone annular structure to a region close to inner circumferential edgesof the at least one carcass ply; wherein forming each carcass plycomprises: preparing a first and a last strip length; preparingintermediate strip lengths, each intermediate strip length comprisinglongitudinal and parallel thread elements at least partly coated with atleast one layer of raw elastomer material; and depositing theintermediate strip lengths onto a toroidal support in a substantiallyU-shaped conformation about a profile in transverse section of thetoroidal support; wherein each intermediate strip length comprises: twoside portions that substantially extend in planes orthogonal to ageometric axis of rotation of the toroidal support atmutually-spaced-apart positions in an axial direction; a crown portionthat extends at a radially outer position in a plane substantiallyparallel to the geometric axis of rotation of the toroidal support; andtwo mutually-axially-spaced-apart transition regions that are definedbetween the side portions and the crown portion, respectively; whereinthe crown portions of the intermediate strip lengths are disposedconsecutively in side-by-side relationship along a circumferentialextension of the toroidal support, wherein edges of circumferentiallyconsecutive intermediate strip lengths abut uniformly along their entirecrown portions extending between the transition regions, wherein eachside portion of each intermediate strip length covers in part a sideportion of a first circumferentially consecutive strip length and ispartly covered by a side portion of a second circumferentiallyconsecutive strip length, wherein forming the at least one annularstructure comprises depositing at least one first elongated element insubstantially concentric coils to form a first circumferentiallyinextensible annular insert, substantially in a form of an annulus,wherein the side portions of the intermediate strip lengths are notturned up around the first annular insert, and wherein the carcassstructure does not comprise flippers wound about the at least oneannular structure.
 30. The method of claim 29, wherein the intermediatestrip lengths are prepared by cutting actions executed sequentially onat least one continuous strip element incorporating the thread elementsin the at least one layer of raw elastomer material.
 31. The method ofclaim 30, wherein each cutting action is followed by deposition of anindividual intermediate strip length thus obtained onto the toroidalsupport.
 32. The method of claim 29, wherein the side portions ofcircumferentially consecutive intermediate strip lengths on the toroidalsupport converge toward the geometric axis of rotation of the toroidalsupport.
 33. The method of claim 29, wherein an amount of coverage ofthe side portions of the intermediate strip lengths progressivelydecreases, starting from a maximum value at radially inner ends of theside portions until a zero value at the transition regions.
 34. Themethod of claim 29, wherein the intermediate strip lengths aresequentially deposited onto the toroidal support according to acircumferential distribution pitch corresponding to a width of theintermediate strip lengths.
 35. The method of claim 29, wherein theintermediate strip lengths are sequentially deposited onto the toroidalsupport according to a circumferential distribution pitch correspondingto a multiple of a width of the intermediate strip lengths.
 36. Themethod of claim 29, wherein the intermediate strip lengths have a widthcorresponding to a submultiple of a circumferential extension of thetoroidal support, as measured at an equatorial plane of the toroidalsupport.
 37. The method of claim 29, further comprising: sequentiallypressing the side portions of each intermediate strip length to defineregions of increased width close to inner circumferential edges of thecarcass structure.
 38. The method of claim 37, wherein the intermediatestrip lengths are prepared by cutting actions executed sequentially onat least one continuous strip element incorporating the thread elementsin the at least one layer of raw elastomer material, and whereinsequentially pressing the side portions is carried out on the at leastone continuous strip element before execution of corresponding cuttingactions.
 39. The method of claim 37, further comprising: moving thethread elements in the intermediate strip lengths apart from each otherconcurrently with sequentially pressing the side portions.
 40. Themethod of claim 29, wherein during depositing the intermediate striplengths, at least one of the intermediate strip lengths is held on thetoroidal support by a suction action produced through the toroidalsupport.
 41. The method of claim 29, wherein depositing the intermediatestrip lengths comprises: laying down each intermediate strip lengthtransversely and at a centered position relative to an equatorial planeof the toroidal support; radially moving each intermediate strip lengthclose to the toroidal support to form the crown portions of theintermediate strip lengths on the toroidal support; translating oppositeends of each intermediate strip length substantially radially close tothe geometric axis of rotation of the toroidal support for applying theside portions of the intermediate strip lengths to the toroidal support;and rotating the toroidal support through an angular pitch correspondingto a circumferential distribution pitch of the intermediate striplengths.
 42. The method of claim 29, further comprising: pressing theside portions of the intermediate strip lengths against side walls ofthe toroidal support.
 43. The method of claim 29, wherein forming the atleast one carcass ply comprises: forming at least one first carcass ply;and forming at least one second carcass ply superposed on the at leastone first carcass ply.
 44. The method of claim 29, further comprising:coating the toroidal support with at least one sealing layer or linermade of an elastomer material impervious to air prior to forming the atleast one carcass ply.
 45. The method of claim 44, wherein coating thetoroidal support is carried out by winding at least one ribbon band ofan air-proof elastomer material in coils disposed side-by-side along theprofile in transverse section of the toroidal support.
 46. The method ofclaim 29, further comprising: disengaging the tire from the toroidalsupport; introducing an air tube into the carcass structure; andvulcanizing the tire.
 47. The method of claim 29, further comprising:vulcanizing the tire; and stretching the carcass structure duringvulcanizing to achieve an expansion of the tire of a linear amountbetween 2% and 5%.
 48. The method of claim 29, further comprising:depositing at least one second elongated element in substantiallyconcentric coils to form a second circumferentially inextensible annularinsert substantially in a form of an annulus disposed concentrically ina side-by-side relationship relative to the first annular insert; andforming at least one filling body of raw elastomer material interposedbetween the at least one first elongated element and the at least onesecond elongated element.
 49. The method of claim 48, wherein the atleast one first elongated element and the at least one second elongatedelement are deposited into a molding cavity, and wherein the at leastone filling body is formed in the molding cavity.
 50. The method ofclaim 48, wherein at least one of the substantially concentric coils ofthe first annular insert, the second annular insert, or the first andsecond annular inserts is defined by a continuous spiral of one or moreelongated elements.
 51. The method of claim 48, wherein at least one ofthe substantially concentric coils of the first annular insert, thesecond annular insert, or the first and second annular inserts isdefined by concentric rings of one or more elongated elements.
 52. Themethod of claim 49, wherein the at least one filling body is formed inthe molding cavity by: interposing at least one annular element of rawelastomer material of predetermined volume between the first and secondannular inserts; and reducing a volume of the molding cavity to compressand deform the at least one annular element until the at least oneannular element, the at least one first elongated element, and the atleast one second elongated element fill the molding cavity.
 53. Themethod of claim 49, wherein the at least one filling body is formed inthe molding cavity by injecting raw elastomer material between the firstand second annular inserts.
 54. The method of claim 48, wherein eachannular structure is interposed between at least one first carcass plyand a second carcass ply superposed on the at least one first carcassply.
 55. The method of claim 48, further comprising: coating one or moreof the at least one first and second elongated elements with at leastone layer of raw elastomer material; wherein each coated elongatedelement is coated prior to depositing the coated elongated element. 56.The method of claim 49, further comprising: magnetically retaining atleast one of the first and second annular inserts at a predeterminedposition within the molding cavity.
 57. A method of making a tire, thetire comprising a carcass structure and at least one circumferentiallyinextensible annular structure, comprising: forming at least one carcassply of the carcass structure; forming the at least one annularstructure; and applying the at least one annular structure to a regionclose to inner circumferential edges of the at least one carcass ply;wherein forming each carcass ply comprises: preparing a first and a laststrip length; preparing intermediate strip lengths, each intermediatestrip length comprising longitudinal and parallel thread elements atleast partly coated with at least one layer of raw elastomer material;and depositing the intermediate strip lengths onto a toroidal support ina substantially U-shaped conformation about a profile in transversesection of the toroidal support; wherein each intermediate strip lengthcomprises: two side portions that substantially extend in planesorthogonal to a geometric axis of rotation of the toroidal support atmutually-spaced-apart positions in an axial direction; a crown portionthat extends at a radially outer position in a plane substantiallyparallel to the geometric axis of rotation of the toroidal support; andtwo mutually-axially-spaced-apart transition regions that are definedbetween the side portions and the crown portion, respectively; whereinthe crown portions of the intermediate strip lengths are disposedconsecutively in side-by-side relationship along a circumferentialextension of the toroidal support, wherein edges of circumferentiallyconsecutive intermediate strip lengths abut uniformly along their entirecrown portions extending between the transition regions, wherein eachside portion of each intermediate strip length covers in part a sideportion of a first circumferentially consecutive strip length and ispartly covered by a side portion of a second circumferentiallyconsecutive strip length, wherein forming the at least one annularstructure comprises depositing at least one first elongated element insubstantially concentric coils to form a first circumferentiallyinextensible annular insert, substantially in a form of an annulus,wherein the side portions of the intermediate strip lengths are notturned up around the first annular insert, and wherein the first annularinsert comprises a radially elongated cross-sectional profile.
 58. Amethod of making a tire, the tire comprising a carcass structure and atleast one circumferentially inextensible annular structure, comprising:forming at least one carcass ply of the carcass structure; forming theat least one annular structure; and applying the at least one annularstructure to a region close to inner circumferential edges of the atleast one carcass ply; wherein forming each carcass ply comprises:preparing a first and a last strip length; preparing intermediate striplengths, each intermediate strip length comprising longitudinal andparallel thread elements at least partly coated with at least one layerof raw elastomer material; and depositing the intermediate strip lengthsonto a toroidal support in a substantially U-shaped conformation about aprofile in transverse section of the toroidal support; wherein eachintermediate strip length comprises: two side portions thatsubstantially extend in planes orthogonal to a geometric axis ofrotation of the toroidal support at mutually-spaced-apart positions inan axial direction; a crown portion that extends at a radially outerposition in a plane substantially parallel to the geometric axis ofrotation of the toroidal support; and two mutually-axially-spaced-aparttransition regions that are defined between the side portions and thecrown portion, respectively; wherein the crown portions of theintermediate strip lengths are disposed consecutively in side-by-siderelationship along a circumferential extension of the toroidal support,wherein edges of circumferentially consecutive intermediate striplengths abut uniformly along their entire crown portions extendingbetween the transition regions, wherein each side portion of eachintermediate strip length covers in part a side portion of a firstcircumferentially consecutive strip length and is partly covered by aside portion of a second circumferentially consecutive strip length,wherein forming the at least one annular structure comprises depositingat least one first elongated element in substantially concentric coilsto form a first circumferentially inextensible annular insert,substantially in a form of an annulus, wherein the side portions of theintermediate strip lengths are not turned up around the first annularinsert, and wherein the substantially concentric coils are disposed inmutual side-by-side relationship according to circumferences ofincreasingly growing diameter about a geometric winding axis of thesubstantially concentric coils.